U.S. patent application number 16/809549 was filed with the patent office on 2020-06-25 for viscous material discharge device.
This patent application is currently assigned to KAWASAKI JUKOGYO KABUSHIKI KAISHA. The applicant listed for this patent is KAWASAKI JUKOGYO KABUSHIKI KAISHA. Invention is credited to Toshihiko Ito, Naohiro Otsuki, Akihito Sakai.
Application Number | 20200197974 16/809549 |
Document ID | / |
Family ID | 65634015 |
Filed Date | 2020-06-25 |
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United States Patent
Application |
20200197974 |
Kind Code |
A1 |
Otsuki; Naohiro ; et
al. |
June 25, 2020 |
VISCOUS MATERIAL DISCHARGE DEVICE
Abstract
A controller controls a plunger to operate at a measurement
speed and discharge the viscous material from the nozzle before
applying the viscous material to the workpiece. The controller
measures a period of time, from when the plunger starts operating
at the measurement speed until a discharge amount of the viscous
material reaches a predetermined value, as a time delay amount. The
controller further determines an operation speed of the plunger
and/or a moving speed of the nozzle during application of the
viscous material to the workpiece according to the measured time
delay amount.
Inventors: |
Otsuki; Naohiro;
(Kakamigahara-shi, JP) ; Ito; Toshihiko;
(Kakamigahara-shi, JP) ; Sakai; Akihito;
(Gifu-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KAWASAKI JUKOGYO KABUSHIKI KAISHA |
Kobe-shi |
|
JP |
|
|
Assignee: |
KAWASAKI JUKOGYO KABUSHIKI
KAISHA
Kobe-shi
JP
|
Family ID: |
65634015 |
Appl. No.: |
16/809549 |
Filed: |
March 5, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP2018/032667 |
Sep 3, 2018 |
|
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16809549 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B05C 11/1002 20130101;
B05C 5/0216 20130101; B25J 11/0075 20130101; B05C 11/10 20130101;
B05C 5/00 20130101; B05D 7/24 20130101 |
International
Class: |
B05C 11/10 20060101
B05C011/10; B05D 7/24 20060101 B05D007/24; B05C 5/02 20060101
B05C005/02 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 8, 2017 |
JP |
2017-172684 |
Claims
1. A viscous material discharge device that discharges a viscous
material and applies the discharged viscous material to a workpiece
in a bead shape, the viscous material discharge device comprising:
a reservoir that stores the viscous material; an extrusion
mechanism that extrudes the viscous material in the reservoir by a
plunger; a nozzle that discharges the viscous material; a holding
member that holds the nozzle; a nozzle moving mechanism that moves
the holding member and the nozzle held by the holding member; and
processing circuitry configured to control the plunger to operate
at a measurement speed and discharge the viscous material from the
nozzle before applying the viscous material to the workpiece;
measure a period of time, from when the plunger starts operating at
the measurement speed until a discharge amount of the viscous
material reaches a predetermined value, as a time delay amount; and
determine one of an operation speed of the plunger and/or a moving
speed of the nozzle during application of the viscous material to
the workpiece according to the measured time delay amount.
2. The viscous material discharge device according to claim 1,
wherein the processing circuitry determines the operation speed of
the plunger and/or the moving speed of the nozzle according to
another speed determination parameter together with the time delay
amount.
3. The viscous material discharge device according to claim 2,
wherein the other speed determination parameter includes a bead
width of the viscous material measured while applying the viscous
material to the workpiece.
4. The viscous material discharge device according to claim 1,
wherein the processing circuitry further measures a remaining
amount of the viscous material to be discharged.
5. The viscous material discharge device according to claim 1,
wherein the processing circuitry controls a start of application
work at the operation speed.
6. A control device for controlling a viscous material discharge
device that discharges a viscous material and applies the
discharged viscous material to a workpiece in a bead shape, the
control device comprising: processing circuitry configured to
control a plunger, of the viscous material discharge device, to
operate at a measurement speed and discharge the viscous material
from a nozzle for applying the viscous material to the workpiece;
measure a period of time, from when the plunger starts operating at
the measurement speed until a discharge amount of the viscous
material reaches a predetermined value, as a time delay amount; and
determine one of an operation speed of the plunger and/or a moving
speed of the nozzle during application of the viscous material to
the workpiece according to the measured time delay amount.
7. The control device according to claim 6, wherein the processing
circuitry determines the operation speed of the plunger and/or the
moving speed of the nozzle according to another speed determination
parameter together with the time delay amount.
8. The control device according to claim 7, wherein the other speed
determination parameter includes a bead width of the viscous
material measured while applying the viscous material to the
workpiece.
9. The control device according to claim 6, wherein the processing
circuitry further measures a remaining amount of the viscous
material to be discharged.
10. The control device according to claim 6, wherein the processing
circuitry controls a start of application work at the operation
speed.
11. A method for controlling a viscous material discharge device
that discharges a viscous material and applies the discharged
viscous material to a workpiece in a bead shape, the method
comprising: controlling a plunger, of the viscous material
discharge device, to operate at a measurement speed and discharge
the viscous material from a nozzle for applying the viscous
material to the workpiece; measuring a period of time, from when
the plunger starts operating at the measurement speed until a
discharge amount of the viscous material reaches a predetermined
value, as a time delay amount; and determining one of an operation
speed of the plunger and/or a moving speed of the nozzle during
application of the viscous material to the workpiece according to
the measured time delay amount.
12. The method according to claim 11, wherein the determining
includes determining the operation speed of the plunger and/or the
moving speed of the nozzle according to another speed determination
parameter together with the time delay amount.
13. The method according to claim 12, wherein the other speed
determination parameter includes a bead width of the viscous
material measured while applying the viscous material to the
workpiece.
14. The method according to claim 11, further comprising measuring
a remaining amount of the viscous material to be discharged.
15. The method according to claim 11, wherein further comprising
controlling a start of application work at the operation speed.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a bypass continuation of PCT
Application No. PCT/JP2018/032667, filed Sep. 3, 2018, which claims
priority to JP 2017-172684, filed Sep. 8, 2017, both of which are
incorporated herein by reference.
TECHNICAL FIELD
[0002] The present application relates to a device for discharging
a viscous material.
BACKGROUND ART
[0003] At a manufacturing site for vehicles and industrial
machinery, automation of the work of applying a viscous material to
the joint of two parts is underway. For example, a conventional
discharge device may discharge a sealant filled in a cartridge from
a nozzle by pressing a sealant with a pusher. The moving speed of
the pusher is changed between a first period before application of
the sealant and the second period during application. The moving
speed in the first period is set according to the viscosity
estimated based on the temperature, the humidity, and the material
of the sealant.
[0004] However, due to a temperature distribution in the cartridge
and other conditions, the viscosity of the sealant filled in the
cartridge is in a widely distributed state. Therefore, it is
difficult to accurately estimate the viscosity of the sealant. Even
if the moving speed is set according to the estimated viscosity, it
is difficult to control the discharge amount of the sealant as
expected. To increase the estimation accuracy, a large number of
sensors are required, and the discharge device becomes
complicated.
SUMMARY
[0005] A viscous material discharge device according to an aspect
of the present application is a device that discharges a viscous
material and applies the discharged viscous material to a workpiece
in a bead shape. The device comprises a reservoir for storing the
viscous material; an extrusion mechanism for extruding the viscous
material in the reservoir by a plunger; a nozzle for discharging
the viscous material extruded from the reservoir by the plunger; a
holding member for holding the nozzle; a nozzle moving mechanism
for moving the holding member and the nozzle held by the holding
member; and a controller, in which the controller is configured to
cause the plunger to operate at a measurement speed and discharge
the viscous material from the nozzle before applying the viscous
material to the workpiece, measure a time from when the plunger
starts operating at the measurement speed until a discharge amount
of the viscous material reaches a predetermined value as a time
delay amount, and determine an operation speed of the plunger
and/or a moving speed of the nozzle during application of the
viscous material to the workpiece according to the measured time
delay amount.
BRIEF DESCRIPTION OF DRAWINGS
[0006] FIG. 1 illustrates an exemplary configuration of a viscous
material discharge device according to an embodiment.
[0007] FIG. 2 illustrates a block diagram showing a viscous
material discharge device.
[0008] FIG. 3 illustrates a flowchart showing processing executed
by a controller.
DETAILED DESCRIPTION OF THE DRAWINGS
[0009] Hereinafter, embodiments will be described with reference to
the drawings. Throughout the drawings, the same or corresponding
elements are denoted by the same reference numerals, and repeated
description is omitted.
[0010] FIG. 1 illustrates an exemplary configuration of a viscous
material discharge device 1 (hereinafter referred to as discharge
device 1). As shown in FIG. 1, the discharge device 1 includes a
holding member 2 that holds a reservoir 3, an extrusion mechanism
4, and a nozzle 5. The holding member 2 has a base 2a formed in a
long plate shape, and the extrusion mechanism 4, the reservoir 3,
and the nozzle 5 are arranged in this order in the longitudinal
direction of the base 2a. The viscous material 95 is discharged
from the tip of the nozzle 5.
[0011] The discharge device 1 includes a nozzle moving mechanism 6
that moves the holding member 2 and the nozzle 5 held by this. In
the present embodiment, the nozzle moving mechanism 6 is composed
of an industrial vertical articulated robot, and includes a robot
arm 7 having a plurality of joints and a plurality (the same number
of joints) of moving actuators 8 (see FIG. 2) that respectively
drive the plurality of joints. The holding member 2 holding the
nozzle 5 is detachably attached to the tip of the robot arm 7. When
the robot arm 7 operates, the holding member 2 and the nozzle 5
held by this move together with the reservoir 3 and the extrusion
mechanism 4. By moving the nozzle 5 while discharging the viscous
material 95 from the nozzle 5, the discharged viscous material 95
is applied to a workpiece 90 in a bead shape.
[0012] The discharge device 1 may be applied to a vehicle (for
example, an aircraft or an automobile) or an industrial machine
manufacturing site. The viscous material is a material having
viscosity such as a sealant or an adhesive. In the application work
of the sealant at an aircraft manufacturing site, the workpiece 90
may be a segment constituting a cylindrical airframe. Further, a
sealant having high viscoelasticity (for example, a viscosity of
1000 to 2000 Pas) is used, and the tolerance of the bead width is
extremely small.
[0013] The reservoir 3 stores the viscous material 95. In the
present embodiment, the reservoir 3 is a cartridge that is
detachably attached to the holding member 2, and the replenishment
of the viscous material 95 is realized by exchanging the
cartridge.
[0014] The reservoir 3 is formed in a cylindrical shape, and the
reservoir 3 is held by the holding member 2 such that the axial
direction of the reservoir 3 is parallel to the longitudinal
direction of the base 2a A wall on the base end side of the
reservoir 3 constitutes a movable wall 3a that can move in the
axial direction, and an outflow port 3b that allows the viscous
material 95 to flow out is provided on the wall on the distal end
side of the reservoir 3. The nozzle 5 is formed in a tapered cone
shape whose both ends are open, and a base end portion having a
relatively large diameter communicates with the outflow port 3b of
the reservoir 3.
[0015] The extrusion mechanism 4 extrudes the viscous material 95
in the reservoir 3. The extrusion mechanism 4 includes a plunger 9
that extrudes the viscous material 95 in the reservoir 3, and an
extrusion actuator 10 that actuates the plunger 9. The plunger 9 is
disposed so as to be linearly movable in the axial direction of the
reservoir 3 or the longitudinal direction of the base 2a. The
extrusion actuator 10 is an electric motor as an example. In that
case, the extrusion mechanism 4 includes a motion conversion
mechanism 11 that converts the rotational power generated by the
extrusion actuator 10 into a linear thrust and transmits the linear
thrust to the plunger 9. The motion conversion mechanism 11
includes a ball screw mechanism as an example. The extrusion
actuator 10 may be a linear actuator such as a piston. In this
case, the motion conversion mechanism 11 can be omitted.
[0016] When the extrusion actuator 10 is actuated, the plunger 9 is
moved linearly, whereby the movable wall 3a is pushed by the
plunger 9. The movable wall 3a moves to the tip end side in the
axial direction by the thrust of the plunger 9, and the internal
volume of the reservoir 3 becomes small. The viscous material 95 is
extruded to the nozzle 5 through the outflow port 3b by the reduced
volume. The viscous material 95 extruded from the reservoir 3 is
discharged from the tip of the nozzle 5.
[0017] The discharge amount per unit time of the viscous material
95 and the moving speed of the nozzle 5 control the amount (volume
or weight) of the viscous material discharged from the nozzle 5
while the nozzle 5 moves a unit distance, and thereby the bead
width of the viscous material 95 applied to the workpiece 90 is
controlled. The moving speed accuracy of the nozzle 5 is higher
than the discharge amount accuracy of the viscous material 95.
Therefore, in order to improve the control accuracy of the bead
width, it is important to improve the control accuracy of the
discharge amount per unit time of the viscous material 95.
[0018] Even if the rotational force generated in the extrusion
actuator 10, the thrust of the plunger 9, and furthermore the
moving speed of the plunger 9 are the same, the discharge amount
per unit time varies with the passage of time. This is because the
viscosity in the reservoir 3 changes over time, and when the
remaining amount of the viscous material 95 in the reservoir 3
decreases, the pressure transmitted to the tip of the nozzle 5
decreases based on the thrust of the plunger 9.
[0019] The viscous material 95 may be prepared by mixing two
liquids. In this case, as a result of the chemical reaction of the
two liquids, the viscous material 95 exhibits required performance
such as hardness and sealability. As time elapses, the progress of
the chemical reaction in the reservoir 3 varies, and the viscosity
varies greatly accordingly. When the viscous material is prepared
by mixing two liquids, an unused reservoir 3 (cartridge) may be
stored frozen in order to prevent a chemical reaction from
proceeding. In this case, immediately after replacement, the
temperature of the viscous material in the reservoir 3 (new
cartridge) is less than 0.degree. C., which is lower than the air
temperature (for example, 10 to 30.degree. C.) at the work site.
For this reason, the temperature fluctuation range of the viscous
material with the passage of time is large, and thereby the
viscosity is also greatly changed.
[0020] The internal temperature of the reservoir 3 does not rise
uniformly, and the chemical reaction in the reservoir 3 does not
progress uniformly. Therefore, the viscosity is widely distributed
in the reservoir 3.
[0021] In light of the above circumstances, the controller 20 (see
FIG. 2) of the discharge device 1 according to the present
embodiment controls the operation of the extrusion mechanism 4
without depending on the estimation or measurement of the
viscosity, and thereby improves control accuracy of the discharge
amount per unit time.
[0022] FIG. 2 is a block diagram of the discharge device 1
according to the present embodiment. As shown in FIG. 2, the moving
actuator 8 of the nozzle moving mechanism 6 and the extrusion
actuator 10 of the extrusion mechanism 4 are controlled by the
controller 20. The controller 20 is, for example, a computer having
a memory such as ROM and RAM and a CPU, and a program stored in the
ROM is executed by the CPU. The controller 20 may be a single
device or may be divided into a plurality of devices.
[0023] Moreover, the functionality of the controller 20 disclosed
herein may be implemented using circuitry or processing circuitry
which includes general purpose processors, special purpose
processors, integrated circuits, ASICs ("Application Specific
Integrated Circuits"), conventional circuitry, controllers, and/or
combinations thereof which are configured or programmed to perform
the disclosed functionality. Processors and controllers are
considered processing circuitry or circuitry as they include
transistors and other circuitry therein. In this disclosure, any
circuitry, units, controllers, or means are hardware carry out or
are programmed to perform the recited functionality. The hardware
may be any hardware disclosed herein or otherwise known which is
programmed or configured to carry out the recited functionality.
When the hardware is a processor or controller which may be
considered a type of circuitry, the circuitry, means, or units are
a combination of hardware and software, the software being used to
configure the hardware and/or processor.
[0024] In the present embodiment, the program stored in the ROM
includes a program that teaches a moving locus and a moving speed
of the tip of the robot arm 7, and by execution of the program
(that is, playback), the holding member 2 and the nozzle 5 held by
this can be moved as previously taught. The program stored in the
ROM includes a program for deriving a command value for the
rotational speed of the extrusion actuator 10, and the moving speed
of the plunger 9 is controlled by execution of the program.
[0025] The controller 20 is connected with a seating sensor 21 that
detects whether or not the reservoir 3 that is a cartridge is
seated on the holding member 2, a discharge amount sensor 22 that
measures a discharge amount, a bead width sensor 23 that measures a
bead width, and a remaining amount sensor 24 for detecting a
remaining amount of the viscous material 95 in the reservoir 3. In
the present embodiment, a liquid reservoir portion 5a (see FIG. 1)
for storing the viscous material 95 discharged from the nozzle 5 is
provided at the tip of the nozzle 5. The discharge amount sensor 22
may be realized by an optical sensor that detects whether or not
the liquid reservoir portion 5a is filled with the viscous material
95. In this case, the discharge amount sensor 22 is attached to the
holding member 2. The bead width sensor 23 may be realized by an
optical sensor that detects the bead width of the discharged
viscous material 95. In this case, the bead width sensor 23 is
attached to the holding member 2. As described above, in this
embodiment, the moving amount of the plunger 9 is linearly
correlated with the total amount of the viscous material 95
extruded from the reservoir 3 to the nozzle 5, or conversely, with
the remaining amount of the viscous material 95 in the reservoir 3.
Therefore, the remaining amount sensor 24 may be realized by a
linear encoder that detects the moving amount of the plunger 9.
[0026] FIG. 3 is a flowchart showing processing executed by the
controller 20. If it is detected that the reservoir 3 is seated on
the holding member 2 based on the detection signal of the seating
sensor 21 (S1: YES), the remaining amount of the viscous material
95 is detected by the remaining amount sensor 24 (S2). At the first
time, the plunger is in the initial position, and the reservoir 3
is fully filled.
[0027] Next, the extrusion actuator 10 is actuated to operate the
plunger 9 at a predetermined measurement speed (S3). As a result,
the viscous material 95 is discharged from the nozzle 5. In the
present embodiment, the viscous material 95 discharged from the
nozzle 5 is accumulated in the liquid reservoir portion 5a. The
counting of elapsed time (time delay amount) from the start of the
operation of the plunger 9 is started by the internal timer of the
controller 20 (S4). The time delay amount is the time from when the
plunger 9 starts operating at the measurement speed until the
discharge amount of the viscous material 95 reaches a predetermined
value. In the present embodiment, the "time to reach a
predetermined value" is the time until the discharge amount sensor
22 detects that the viscous material 95 is filled in the liquid
reservoir portion 5a. When the discharge amount of the viscous
material 95 reaches a predetermined value (S5: YES), the counting
of elapsed time is finished and the elapsed time up to this point
is measured as a time delay amount (S6).
[0028] Next, the operation speed of the plunger 9 is determined
according to the measured time delay amount and other speed
determination parameters. When the time delay amount is large, the
viscosity of the viscous material 95 is relatively high and the
discharge amount per unit time is small, so the operation speed of
the plunger 9 is increased. The reverse is true when the time delay
amount is small. The speed determination parameter will be
described later.
[0029] Next, the application work is started using the determined
speed (S8). In the application work, first, the nozzle moving
mechanism 6 is actuated to move the nozzle 5 to the application
start position of the viscous material 95. Thereafter, the
extrusion actuator 10 is actuated so that the plunger 9 operates at
the determined operation speed, and the moving actuator 8 is
actuated so as to move the nozzle 5 at a predetermined moving
speed. As a result, the viscous material 95 is applied to the
workpiece 90 in a bead shape. During this application work, the
bead width is measured by the bead width sensor 23 (S9). When the
nozzle 5 moves to a predetermined application end position, the
application work is terminated (S10). In this termination process,
as an example, the extrusion actuator 10 is actuated so that the
plunger 9 is slightly moved in the reverse direction, whereby the
discharge of the viscous material 95 from the nozzle 5 is stopped.
Once the flow is finished, the flow is restarted from step S1 to
perform the next application work.
[0030] Thus, the time delay amount increases as the viscosity
increases. Since the speed is determined according to parameters
that are determined according to a viscosity, not parameters such
as a viscosity having a wide distribution in the reservoir or a
temperature that affects this, the amount of application of the
viscous material per unit length in the bead extending direction,
or the control accuracy of the bead width of the applied viscous
material is improved.
[0031] Similarly to the above, the operation speed of the plunger 9
in the next application work is determined in advance of the next
application work. That is, the remaining amount of the viscous
material 95 in the reservoir 3 is measured (S2), and the time delay
amount is measured by operating the plunger 9 at the measurement
speed (S3 to S6). The measurement speed may be set to the same
speed each time, and after the second time, the operation speed of
the plunger 9 set in the previous application work may be used. In
the speed setting after measuring the time delay amount (S7), the
operation speed of the plunger is reset according to the measured
time delay amount and the speed determination parameter.
[0032] The speed determination parameter includes the remaining
amount of the viscous material 95 and the bead width measured
during the previous application work. As the remaining amount of
the viscous material 95 decreases, the discharge amount per unit
time decreases even in the same discharge operation. When the
remaining amount of the viscous material 95 decreases, the
operation speed is corrected so as to increase. If the bead width
is smaller than the required one, the operation speed is corrected
so as to increase so that the discharge amount per unit time
increases. In the next application work, the controller 20 actuates
the extrusion actuator so as to operate the plunger 9 at the
operation speed thus determined (S9). Note that the bead width is
measured also during the application work (S10). In this way, the
application work is repeated, and a plurality of bead-like viscous
materials 95 are applied to the workpiece 90.
[0033] According to the above configuration, the operation speed of
the plunger 9 is determined according to a time delay amount that
is a parameter determined according to the viscosity, not a
parameter such as a viscosity having a wide distribution in the
reservoir 3 or a temperature or the like that affects the
viscosity. Therefore, the control accuracy of the application
amount of the viscous material per unit length in the bead
extending direction or the bead width of the applied viscous
material 95 is improved. In particular, if the temperature change
range until the reservoir 3 becomes empty is large because it is
stored frozen until just before loading, the viscous material 95 is
prepared by mixing two liquids that cause a chemical reaction, or
the viscous material 95 has a property of curing with the passage
of time, the viscosity changes in a complicated manner with the
passage of time. In this embodiment, since the operation speed is
determined based on the time delay amount that appears as a result
of the change, the discharge amount control accuracy can be
maintained high.
[0034] The operation speed of the plunger 9 is determined according
to not only the time delay amount, but also the remaining amount of
the viscous material in the reservoir 3. It is possible to cope
with a decrease in the discharge amount accompanying a decrease in
the remaining amount, and it is possible to maintain a high control
accuracy of the discharge amount until the viscous material 95 in
the reservoir 3 becomes empty from the fully filled state.
[0035] In the present embodiment, also feedback control in which
the bead width is measured is further incorporated, so that even if
the bead width tolerance is small and severe, the bead width can be
kept within the required range.
[0036] Note that the controller 20 stores a correspondence
relationship between the time delay amount and the speed
determination parameter and the operation speed of the plunger 9 in
the memory. Based on the measured value, the controller 20 refers
to this correspondence relationship and determines the operation
speed. This "correspondence relationship" may be a map, a lookup
table, or an arithmetic expression. The form of the correspondence
relationship is not particularly limited, but the derivation of the
correspondence relationship is performed before implementation in
the memory of the controller 20 through an experiment.
[0037] Although the embodiment has been described so far, the above
configuration is merely an example and can be appropriately
changed, added, and/or deleted.
[0038] In the above embodiment, the operation speed of the plunger
is variably set based on the time delay amount for controlling the
bead width, but the moving speed of the nozzle 5 may be variably
set in addition to or instead of the operation speed of the
plunger.
REFERENCE SIGNS LIST
[0039] 1 discharge device [0040] 2 holding member [0041] 2a base
[0042] 3 reservoir [0043] 3a moveable wall [0044] 3b outflow port
[0045] 4 extrusion mechanism [0046] 5 nozzle [0047] 5a liquid
reservoir portion [0048] 6 nozzle moving mechanism [0049] 7 robot
arm [0050] 8 moving actuator [0051] 9 plunger [0052] 10 extrusion
actuator [0053] 11 motion conversion mechanism [0054] 20 controller
[0055] 21 seating sensor [0056] 22 discharge amount sensor [0057]
23 bead width sensor [0058] 24 remaining amount sensor [0059] 90
workpiece [0060] 95 viscous material
* * * * *